Method of forming cementitious bodies and material for use in same



E. P. MARSHALL METHOD OF FORMING CEMEXTITIOUS BODIES AND MATERIAL FOR USE IN SAME Filed Oct. 4, 1928 2 Sheets-Sheet l JNVENTOR. [ar/ P Mars/m BY M ATTO EV;

28, 1933. E p MARSHALL 1,899,101

METHOD OF FORMING CEIENTITIOUS BODIES AND MATERIAL FOR USE IN SAME Filed Oct. 4, 1928 2 sh ets-sheet 2 INVEN TOR.

Enr/ F. Mars/1a A TTORNEYS Patented Feb. .28, 1 933 s'izraras QRATJE NT orifice 11 MARSHALL, or. LosANenLns, CALIFORNIA METHOD OEYFORMING CEMENTXT'IOUS BODIES AND MATERIAL FORv USE IN SAME mpplicati on filed. October 4,- 1928. Serial N0. $10,278.

This. lHVGHtlOIlFIGlfiiGS to the forming, pouring or castingof 'cementitious bodies,

such as concrete walls structures, blocks and the like and particularly to a method of formingsuch bodies in such a. manner as. to modify the surface -:thereof land to. a "mate rial a daptedfor useiin said method. The modification of the surface maycconsist feither in"modifyingathei-texture,:form, orconfiguration thereofv or 1I1JpIOVldlI1'g.;a-11y,l6-

sired coloring i thereon,: or a combination of both texture and color modification, and it may also include the imparting of swaterproof or water 'resistant properties to the surface ofthe concrete.

An important object of" the invention is: to

form cementitious bodies :having pleasing surface effects withoutrrequiring. the subsequent application of surface coatings or coloring thereto; or 1 any other treatment after the removal of theforms. This objectI accomplish in generalv by pouring or casting the concrete or other cementitious material ofwhich the body is to'be formed, ina form provided with a modifying layer or coating a daptedto be transferred to andbecome bodily incorporated in the -surface= layer .of the concretebody, and to produce the desiredsurface efiecnwhen said'bo'dy becomes set, so that upon removal of the form the surface of the body will-"have the desired *finishedappearance.

A particular object'of the invention is to form cementitious bodies in such -manner that a pleasing surface of a permanent character is provided thereon,-thisfpermanence being due to the. fact that'the desiredeffect of color, form, configuration, texture, or re- 7 sistanceto-water penetrationis produced by surface modifying agents {integrally incor-- for example colored building 'stone,=terra cotta, stucco, or block or'artificial stone construction of var oussorts, maywbe produced upon the surface of concrete structures or other cementitious bodies, minimum -cost,-and with a minimumexpenditure-of time and labor.

.Other objects of the invention will be ap-' parent. from the description hereinafter..- F .The; accompanying drawings illustrate my -1nvent1on;andreferring: thereto Fig. his a perspective view ofa sheet of material adapted' for usein lining forms or molds according tomy: invention.

Fig.2 is a perspective-view of a lined with sheets ,of material adapted 'to modify the surface thereof.

.Fig. 3 is a face'view of a portion of a concrete-wall. made in aform such asshown I 1n-.F1g. 2.

Fig. 4 is a face view of one of the walls of a concrete form showing a modified ,method of placing .the sheets of surface 7 of the walls of a form showing another pos- ,sib'le modification in the method of placing the sheets of surface modifying material thereon. v

, Fig.-7 is a face view of a portion ofa concrete wall produced bythe form shown-in Fig-,6. v

Fig. 8 1s aview of a portionof a form, or

.mold, for-use in pouring or casting'a con crete body, in which the surface modifying 4 coating is applied directly to the-interior surface of said form or mold.

According-to a preferred embodiment of .this invention I employ, for the purpose of lining or covering the interior of forms, or

.molds for use in pouring concrete or other ,cementitious bodies, material in the form of sheets havinga coating of surface-modifying material on the outer face thereof. .Each of said sheets, such as indicated-at l :in Fig. 1,,may comprisea base of'sheet material 2 of suitable'thickness to provide 5 the necessary strength without undue weight, for example from inch, or possibly less I in the case of metal sheets, to inch or more. Said sheets may be of any suitable 9 form for 60 pouring a'concretewall, said .formbemg.

size convenient for handling and suitable for the purpose for Which they are to be used of thickness and dimensions are given by 7 or other cementitious body.

Way of example only and'that the invention is not limited in this respect. This sheet material may consist for example of paper, cardboard, boxboard, strawboard, Wallboard, or 7 other composition board, or V of sheet metal, Wood, canvas, or other fabric material, or in general of any sheet material adapted toform a base or backing for application of a coating of surface-modifying material.

Thesheet shovvn'in Fig. 1 is provided upon one face With a coating of surface-modifying material 3 applied thereto in such manner as to adhere during shipping or handling of the sheets and during the placing thereof in the forms. Such coating may comprise,

for example, a suitable adhesive binding material adapted to form a bond to the sheet 2, and any suitable surface-modifying ingredients incorporatedin said binding material. Said binding material may consist, for ex ample, of glue, mucilage,'or other adhesive material which is readily soluble in WZI'EGIO]! adapted to soften upon application of Water and the binding material, Well as the surface modifying ingredients, should be adapted to permit substantially normal setting of the concrete in contact therewith so that the binding material and the surfacemodifying ingredients carried thereby will actually enter into the surface of the concrete When poured and become an integral part of the surface layer thereof When set.

The surface-modifying ingredients carried by said binding material may include agents adapted to modify either the texture or the 'color,or both, of the surface of the concrete For the purpose of modifying the texture or form, I may use for example, aggregates of various sorts, such as, rock, sand, shell, etc, or mixtures thereof, or I may use chemicals which will form gases upon contact of the Wet concrete or cementitious material therewith so as to produce a pitted surface.

For modifying the color of the cementitious material I may use colored aggregate such as colored rock, shell or sand, or pigments of suitable color, or any other coloring material, such as dyes, or I may use chemicals adapted to react with one another or With constituents of the cementitious ma: terial to produce the desired color eflects, all of such color modifying agents being, as above stated, incorporated in the binding material to form the coating 3 on the base 2 of sheet material to be used in lining the forms.

The general method of making the above described sheet material may consist in first applying to the surface of the base material 2, While preferably in the form of relatively large sheets, the binding material such as above mentioned, and then applying thereto the surface modifying agents such as above mentioned as by sprinkling, dusting, blowing or pouring the same thereon, so as to cause'such agents to become incorporated therein or to adhere thereto.

If desired, however, the surface modifying constituent may first be incorporated or mixed with the binding material and the mixture then applied as a coating on the base material. The expression incorporated therein, as used herein in this connection, is therefore to be understood as covering either a distribution of the surfacemodifying agents throughout all or part of the coating of binding material or simple adherence of such agents to the surface of a such coating.

The composite sheets so formed are then dried, after which they may be cut or torn into sheets of any desired size or shape for shipment or use. 7

The following may be given as a specific cording to my invention, for use in lining molds. Sheets of strawboard are coated on one side with'a' thin coating of common glue, such as sizing glue, Which is soluble in Water, and aggregate consisting of crushed rock, crushed shell, sand and powdered rock, together with coloring agents consistinw of iron sulphate (FeSO and Vermilion f cinnabar, HgS), are sprinkled or dusted over the surface of the Wet glue so as to adhere thereto. It will be understood, of course,

that any'of the other forms of texture modifyingorcoloring modifying agents above mentioned may be used instead of or in addition to these. Furthermore, the several agents may be applied uniformly over the surface or different agents may be applied on different parts of the surface. Particularly effective results may be obtained, for example, by the selective application of different-coloring agents to different portions of the surface so as to produce a mottled effect on the concrete;

7 The sheets are then subjected to a drying operation so as to cause the glue to harden, after Whichthey may be cut into blocks of suitable. size. 7

In using the sheet material of any of the types above described in the forming of cementitious bodies, the same may be applied in, any suitable manner to the interior of forms or molds'in. which such bodies are to be poured or cast.

In Fig. 2, for example, I have shown a form for pouringa concrete wall. Such form consists as usual of two spaced Walls 5 example of one form of sheet material aceach composed of boards. laid horizontally and secured to upright 'supports'fi or to any other suitable supporting means. "The sheets tween staggeredor offset in successive'horlzontal rows, as indicated, in the same man nerin which bricks or stone blocks are ordinarily'laid. The sheets may bese'cured' to the forms in any suitable manner as by means of nails, tacks, clips, or otherfasterr If both sides'of the concrete *ing devices;

wall are to beexposed to view, bothside walls ofthe form are preferably lined with the-sheet material,;while if only one side of the wall is to be exposed or is desired tobe finished accordingto this method, only the form needs'to the corresponding wall'of be lined in this manner. The walls of the form may be first erected and then lined; 4 with the sheet material, or said walls maybe assembled in sections and the sheet material applied thereto, and these lined sections then erected in position.

The mixed concrete, consisting of the usual mixture of Portland cement, sand, and

aggregate, with water, is then poured bebrown 1ron oxide, giving a characteristic IGfldlSll brown color,-wh1ch will occur notmerely as a thin film or layer uponv the surface of the'concrete but distributed to aconsiderable depth therein, so that the color tween the walls of the form in the usual manner and allowed to harden or sets 2 Upon contact of the wet concrete'with the surface modifying coating jd ofthe sheet material, such coating is caused to i exercisethe' desired eiiect'upon the surfacelayerof'the concrete, the nature of this effect depending upon the surface-modifying ingredients con- -ta'inedi'in such coating. The glue or other water soluble binding matcrialwillbe :dis. solved or softened by the waterin the -con-. c-rete, and the surface-modifying agents will enter into or adhere toiand become incorpo-- "rated as an integral part ofthe concrete: Texture modifying agents such. as the shell, sand and roclrof the above example will" become embedded or will adhere to the. surface of the concrete and form asurfaceof'the desired texture, while color modifyingagents will penetrate to a greater or less extent into the concrete and impart the desired colors to the surface thereof." If such coloringagents consist of dyes or pigments such as the veranilion in the above example, such materials will simply be transferred tothe concrete and form a colored coating or surface thereon.

In any event, the binding material acts'as ayehiclefor first holding the desired surface-modifying agents in position on the surfaceof' the base material until thejconcrete is poured, and for then: transferring such surface-modifying agentsbedily to the 1 fairly closely and substantially flush with 'wetconcrete so as to become integrally incorporated in" the surfacelayer of'thc-cong ,3 will be produced, the wall having a form 1 or/conliguration suchas to give .the appearcrete body whenthe sameis set; It has here- Ltofore been proposed to apply tothe; forms,

layer of the cementitious materialwill before pouring the wet cementitious material therein, a coating of cementiidestroying material or so-called' medication adapted to prevent setting or development ofa bond 3 in the outerlayer of the concrete in contact therewith, so that upon removal of the forms and of the said coating,:the outer either fallo'ff or may be readily removed. This,

,however, is'quite different from my procedure, in whichithesurface layer-of the concrete is permitted to set in normalv manner, and in" which substantiallytheentlre layer of binding materlal and surface-.inodlifying *material is transferred into the surface :layer. of the concrete andbecomes integrally incorporated III the set concrete. body.

If, on the other hand, chemical-coloring agents, such as the iron sulphate of theabove example are used,; these agents will' penetrateinto the concrete and willthere-rreact with constituents of the concrete orwitlrone another to cause precipitation of substances of the desired color. .For. example, the-iron sulphate will react with the alkaline materials in the concrete to: probably EfiI'SlI'fOIIII? a hydrous ferric'oxide which upon drying and exposure to air Wlllbfl converted to a reddish thus imparted will beof a'highly permanent anydesired color effects may be produced upon the surface. of the concrete. single cc-loring agentmay be provided on .the en tire surface of all of the sheet materialthus giving a plain uniform color effect over the -.entiresurface of the wall, or different color- .ing agents may be applied to different portions of all of the sheets, producing amottled'effect. A-somewhat different effect can also be obtained by. theuseof onlya single coloring agent on each sheet, and placing sheets Wllll. different coloring. agents in uxtapositlon so as togive the effect of blocks'of 'stonesof various colors or shades. It is evidentthat not only the color, butalso thetexture of different portions of thewa'll maybe varied .in a similar manner so as-to give pleasing and harmonious effect-s.

After the concrete has set sufliciently the forms maybe removed in the usualnianner and the base material of the respectivesheets ma be stri 3 ed from the concrete leavin b aconcrete wall with a surface of-a texture and color formed as above described. If the sheets. are laid in the; manner shownin Figx2= with their adjacentedges abutting one another, an effectsuch as shown iniFig.

ance of being formed of blocks. or stones of the size and shape of the sheets used for lining the forms, and separated by fine ridges or ledges 8 due to the small cracks or slight departures from a smooth plane of the adjoining edges'of adjacent sheets.

As illustrated in Figs. 4 and 5 a somewhat different efi'ect can be secured by spacing the sheets 3 slightly, apart in applying the same to a form wall 5 so as to provide grooves or channels 10 therebetween. The concrete wall produced in a form lined in this manner will have the appearance shown in Fig. 5, the effect being that of blocks or stones with raised beads or rid 'es ofpointing material therebetween as indicated at 11. A different efiect can also be secured by applying narrow strips of wood, cardboard or the like as indicated at 12 in Fig. 6 over of cementitious bodies dur1ng setting comthe joints 18 between adjacent sheets, such strips also serving, if desired, to secure the sheets to the form. Similar strips may also be placed at intervals over the surface of the sheets if desired. As shown in Fig. 7 the wall produced in this. manner has the appearance of a wall of blocks or stones, the joints between which are filled with pointing material but are recessed somewhat with respect to the faces of the blocks so as to provide grooves 14 therebetween.

. In addition to the above, many varied and artistic effects of form or configuration may be secured by using the sheet material in different ways. For example the mate rial may be torn or cut to form pieces of irregular sizes which may be applied in irregular manner to the formsso as to overlap one another, thus forming an imitation of a rough Spanish texture stucco-finished wall.

If desired, other agents in addition to the texture and color modifying agents above described may also be incorporated in the coating applied to the sheets. WVaterproof ing agents of various sorts may, for example be applied in this manner. As a specific example, powdered or crushed: alum and limestone may be incorporated'therein, being applied for example along with the other surface-modifying agents in the example given above, penetrating into the surface layer of the concrete and reacting to form substances adapted to prevent penetration of water therein, due either to water repellent properties thereof or to mechanical closing of the pores of the concrete.-

Agents may also be used which are adap ed to react with constituents of the concrete or other cementitious mixture to form bubbles of gas which will leave recesses or depressions in the surface of the concrete, giving a pitted effect. Calcium carbide may be used for this purpose, being incorporated with the binding material in the same manner as any of the other surface-modifying given above, powdered or crushed calcium carbide may be sprinkled over the surface of the coating of binding material along with the other surface modifying agents.

As shown in Fig. 8, the surface-modifying coating 3 may be applied directly to the interior of a mold or form instead of applying such coating to sheet material and lining the form therewith. This method of practicing the invention may be used to practical advantage 'forexample, in the casting of blocks or other structural members of concrete or artificial stone composition.

I claim:

1. A material for modifying the surface prising a slieet of base material and a sur face modifying coating applied to one face thereof, said coating comprising a binding material adapted to soften upon contact of wet cementitious materialtherewith, and a water soluble color modifying agent incorporated in said binding material.

2. A material. for modifying the surface of cementitious bodies during setting comprising ashcet of base material and a surface modifying coating applied to one face thereof, said coating comprising a binding material adapted to soften upon contact of wet cementitious material therewith, and a water soluble chemical incorporated therein and adapted to react with constituents of wet cementitious material to produce a colored substance.

3. A material for modifying the surface of cementitious bodies during setting, comprising a sheet of base material and a surface modifying coating applied to one face thereof, said coating being free of set inhibiting material so as to permit substantially normal setting of cementitious material in contact therewith and said coating comprising a binding material adapted to soften upon' contact of wet cementitious material therewith and water soluble colormodifying material incorporated in said binding material.

4. The method of forming cementitious bodies which comprises providing, on the inner face of a form, a modifying layer com prising a binding material llE .V].i water soluble material incorporated therein adapted to modify the color of the surface layer of the cementitious material, said binding material being adapted to soften upon contact of water-containing cementitious material therewith, and said modifying layer being adapted topermit substantially no mal setting of the cementitious material in Contact therewith, supplying water-containing cementitious materialto the interior of said form in contact with said modifying layer, causing the modifying layer to be bodily transferred from the form to the surface layer of the cementitious material,causing the cementitious material to harden and the, binding material and, color-modifying,

material to become incorporated, as an integral part of the hardened surface layer thereof, and then removing the form while leaving the binding material. and colormodifying material permanently incorpo rated in the surface layer of the said cementitious body.

5. A method of forming cementitious bodies which comprises-providing on the inner face of a form, a modifying layer the surface layer of the cementitious niaterial, causing the cementitious material to harden, and the color-modifying material to become incorporated as an integral part of the hardened surface layer thereof, and then removing the form while leaving the color modifying material permanently incorporated in'the surface layer of the said cementitious body. a

6. The method of forming cementitious bodies which comprises providing, on the inner face of the form, a modifying layer comprisinga binding material having incorporated therein material adapted to chemically react with constituents of wet cementitious material to produce coloring material, supplying water-containing cementitious material to the interior of said form in contact with said modifying layer, causingthe cementitious material to. harden and causing coloring material produced as above set forth to become incorporated as an integral part of the hardened surface layer of said cementitious material, and then removing the form while leaving saidcoloring material permanently incorporated in the surface layer of said cementitious body.

7. The method of modifying the surface of cementitious bodies during setting, which comprises bringing into contact withthe surface of a cementitious body during setting thereof a sheet of backing material having on its inner face a modifying layer comprising a binding material having water soluble material incorporated therein adapted to modify the color of the surface layer of the cementitious material, said binding material being adapted to soften upon contact of water-containing cementitious material therewith, and said modifying layer being adapted to permit substantially normalsetting' of the cementitious material in contact therewith, causing the modifying layer to be bodily transferred from said backing material to the surface layer of the cementitious material, causing the cementitious material to harden and the binding material and color-modifying material to become incorporated as an integral part of the hardened surface layer thereof, and then removing said sheet of backing material while leaving the binding material and color-modifying material permanently incorporated in the surface layer of said cementitious body,

8'. The'method of modifying the surface of cementitious bodies during setting, which,

I comprises bringing into contact with the surface of a cementitious body during setting thereof a sheet of backing material having on its inner face a modifying layer comprising a binding material having incorporated therein water soluble material adapted to modify the color of the surface layer of cementitious material brought in contact therewith, causing the color-modifying ma-' terial to be bodily transferred from the form to the surface layer of the cementitious material, causing the cementitious material to harden and the color-modifying material to become incorporated as an integral part of the hardened surface layer thereof, and then removing said sheet of backing material while leaving the color-modifying material permanently incorporated in the surface layer of said cementitious body.

9. The method of modifying the surface of cementitious bodies during setting, which comprises bringing into contact with the surface of a cementitious body during setting thereof a sheet of backing material having on its inner face a modifying layer comprising a binding material having incorporated therein material adapted to chemically react with constituents of wet cementitious material to produce coloring material, causing the cementitious material to harden and the coloring material produced as above set forth to become incorporated as an integral part of the hardening surface layer of said cementitious material, and then removing said sheet of backing material while leaving said coloring material permanently incorporated in the surface layer of said cementitious body. 1 V In testimony whereof I have hereunto subscribed my name this 25th day of Sep- 

